Vacuum insulation structures with adhesives with reduced-

Abstract

A vacuum insulation apparatus includes a cabinet defining at least one compartment. The cabinet body comprises an enclosure and a lining assembly. The cladding and the liner assembly define an insulating cavity therebetween. The insulating cavity is at least partially vacuum. A trim partition assembly is coupled to the cladding and the liner assembly. The trim partition assembly defines an envelope groove for receiving an edge of the envelope and at least one liner groove for receiving at least one edge of the liner assembly. An adhesive is disposed in the cladding groove and the at least one liner groove, the adhesive sealing the insulating cavity. The adhesive includes a sheet-like additive to reduce gas permeation therethrough to maintain the at least partial vacuum in the thermally insulating cavity.

Description

Technical Field

[0001] The present invention generally relates to adhesives with flake additives disposed in decorative partition components of equipment, and more particularly to adhesives with flake additives that reduce gas permeation disposed in decorative partition components of vacuum insulation structures. Summary of the invention

[0002] According to one aspect of the present invention, a vacuum insulation device includes a cabinet defining at least one compartment. The cabinet includes a shell and a liner assembly. The shell and the liner assembly define an insulation cavity therebetween. The insulation cavity is under at least partial vacuum. A decorative partition assembly is coupled to the shell and the liner assembly. The decorative partition assembly defines a shell groove for receiving an edge of the shell and at least one liner groove for receiving at least one edge of the liner assembly. An adhesive is disposed in the shell groove and the at least one liner groove, the adhesive sealing the insulation cavity. The adhesive includes a flaky additive to reduce gas permeation of gas therethrough, thereby maintaining the at least partial vacuum in the insulation cavity.

[0003] According to another aspect of the present invention, a refrigeration device includes a decorative partition assembly that defines an outer shell recess and a refrigerated liner recess. An adhesive is disposed in the outer shell recess and the refrigerated liner recess, wherein the adhesive includes a flaky additive to reduce air infiltration through the adhesive. The outer shell has an edge disposed within the outer shell recess of the decorative partition assembly using the adhesive. The refrigerated liner has an edge disposed within the refrigerated liner recess of the decorative partition assembly using the adhesive. The refrigerated liner defines a refrigerated compartment.

[0004] According to another aspect of the present invention, a method for manufacturing a vacuum insulated cabinet includes: providing a decorative partition component assembly, the decorative partition component assembly defining a shell groove extending along an outer periphery and at least one liner groove extending along a periphery of at least one compartment; mixing an uncured adhesive with a flake additive; and injecting the uncured adhesive with the flake additive into the shell groove and the at least one liner groove. The method also includes positioning an edge of the shell in the shell groove using the uncured adhesive, positioning an edge of at least one liner in the at least one liner groove using the uncured adhesive, and curing the uncured adhesive in the shell groove and the at least one liner groove to form a polymer network that suspends the flake additive to reduce gas permeation therethrough.

[0005] These and other features, advantages and objects of the present invention will be further understood and appreciated by those skilled in the art by referring to the following description, claims and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] In the attached picture:

[0007] Figure 1 is a front perspective view of a refrigeration device according to the present invention;

[0008] Figure 2 is a cross-sectional view of a refrigeration device having a vacuum insulation cabinet and a vacuum insulation door according to the present invention;

[0009] Figure 3 is an exploded side perspective view of a cabinet of a refrigeration device according to the present invention, the cabinet having a shell, a lining assembly and a decorative partition assembly;

[0010] Figure 4 is a side perspective view of a refrigeration device according to the present invention;

[0011] Figure 5 According to the present invention Figure 3 The front elevation of the decorative partition;

[0012] Figure 6 According to the present invention Figure 3 The rear elevation of the decorative partition;

[0013] Fig. 7A is a partial cross-sectional view of a decorative partition component assembly of a cabinet of a refrigeration device according to the present invention;

[0014] Figure 7B is a partial cross-sectional view of a decorative partition component assembly of a cabinet of a refrigeration device according to the present invention;

[0015] Fig. 8A is a partial cross-sectional view of a decorative partition assembly of a cabinet of a refrigeration device according to the present invention, showing an adhesive added to the groove;

[0016] Figure 8B is a partial cross-sectional view of a decorative partition assembly of a cabinet of a refrigeration device according to the present invention, showing an adhesive added to the groove;

[0017] Fig. 9A is a partial cross-sectional view of a cabinet of a refrigeration appliance according to the present invention, showing a decorative partition assembly having an adhesive disposed in a groove, wherein the decorative partition assembly is coupled to an enclosure and a liner assembly;

[0018] Fig. 9Bis a partial cross-sectional view of a cabinet of a refrigeration appliance according to the present invention, showing a decorative partition assembly having an adhesive disposed in a groove, wherein the decorative partition assembly is coupled to an enclosure and a liner assembly;

[0019] Fig.10 is a schematic diagram of particles of a platelet-like additive disposed in a polymer network of an adhesive according to the present invention;

[0020] Fig.11 is a partial cross-sectional view of a decorative partition component assembly of an equipment cabinet having a groove in which an adhesive with a flake-like additive is disposed and an elevation view of a sheet of the flake-like additive according to the present invention; and

[0021] Fig.12 is a flow chart of a method for manufacturing a vacuum insulation structure according to the present invention.

[0022] The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles described herein. DETAILED DESCRIPTION

[0023] The presently illustrated embodiment mainly pertains to a combination of method steps and apparatus components associated with an adhesive having a flaky additive that reduces gas permeation disposed in a decorative partition assembly of a vacuum insulation structure. Therefore, where appropriate, apparatus components and method steps have been represented by conventional symbols in the accompanying drawings, which only show those specific details relevant to understanding the embodiments of the invention, so as to avoid obscuring the invention by details that are obvious to a person of ordinary skill in the art who has benefited from the description herein. In addition, the same reference numerals in the specification and the drawings represent the same elements.

[0024] For the purpose of the description herein, the terms "upper", "lower", "right", "left", "rear", "front", "vertical", "horizontal" and their derivatives shall be used in the same manner as described above. Figure 1 Unless otherwise indicated, the term "front" shall refer to the surface of the element that is closer to the intended observer and the term "rear" shall refer to the surface of the element that is farther from the intended observer. However, it should be understood that the present invention can take various alternative orientations unless expressly indicated to the contrary. It should also be understood that the specific devices and processes shown in the drawings and described in the following description are merely exemplary embodiments of the inventive concepts defined in the appended claims. Therefore, unless the claims expressly state otherwise, specific dimensions and other physical characteristics related to the embodiments disclosed herein should not be considered limiting.

[0025] The terms "include", "comprising" or any other variation thereof are intended to cover a non-exclusive inclusion, such that a process, method, article or apparatus that includes a list of elements includes not only those elements, but may also include other elements not expressly listed or inherent to the process, method, article or apparatus. An element followed by "comprising..." does not, without more limitations, preclude the presence of additional identical elements in the process, method, article or apparatus that includes the element.

[0026] Reference Figures 1 to 12 , reference numeral 10 generally indicates a vacuum insulation device. The vacuum insulation device 10 includes a cabinet 12, which defines at least one compartment, typically including a refrigerated compartment 14 and a frozen compartment 16. The cabinet 12 includes an enclosure 18 (also referred to as an outer enclosure 18) and a liner assembly 20, the liner assembly 20 including at least one liner 20, the liner 20 typically including a refrigerated liner 20a and a frozen liner 20b. The cabinet 12 also includes a decorative partition assembly 22 coupled to the enclosure 18 and the liner assembly 20. The enclosure 18 and the liner assembly 20 define an insulating cavity 24 therebetween. At least a partial vacuum 26 is defined in the insulating cavity 24. The trim partition assembly 22 defines a shell recess 28 for receiving an edge 34 of the shell 18 and at least one or more liner recesses 32 for receiving at least one or more edges 34 of the liner assembly 20, which may include liner recesses 32a and 32b, and the edge 34 of the liner assembly 20 may include edges 34a and 34b. An adhesive 36 is disposed in the shell recess 28 and the liner recess 32. The adhesive 36 seals the insulation cavity 24. The adhesive 36 includes a flake additive 38 to reduce gas permeation therethrough, thereby maintaining at least a partial vacuum 26 in the insulation cavity 24.

[0027] Reference Figure 1 and Figure 2 , the vacuum insulation device 10 is shown as a refrigeration device, however, it is contemplated that the vacuum insulation device 10 disclosed herein can be used in various devices, structures, panels or components for insulation purposes other than devices. The refrigeration device 10 is shown as a bottom-mounted refrigerator having an upper compartment configured as a refrigeration compartment 14 and a lower compartment configured as a freezer compartment 16.

[0028] The cabinet 12 of the refrigeration device 10 shown includes a first insulated door 50a and a second insulated door 50b. The first insulated door 50a and the second insulated door 50b (which may be collectively referred to as insulated door 50) may have a substantially similar configuration, as further discussed herein. In this manner, the insulated doors 50a and 50b may respectively seal the refrigeration compartment 14 and the freezer compartment 16 defined by the cabinet 12. In addition, in various implementations, the device 10 includes a cabinet 12, which defines at least one compartment, which may include a first compartment (e.g., refrigeration compartment 14) and a second compartment (e.g., freezer compartment 16) sealed by the insulated door 50. The device 10 may be, for example, a bottom-mounted French door refrigerator, a top-mounted refrigerator, a side-by-side refrigerator, a 4-door French door refrigerator, and / or a 5-door French door refrigerator. In addition, the present invention is not limited to refrigerators. The device 10 may be, for example, a freezer, a cooler, a vacuum insulation structure, and other similar devices and fixtures within a home and commercial environment.

[0029] The cabinet 12 of the apparatus 10 is an insulated structure having an insulated cavity 24 defined between an enclosure 18 and a liner assembly 20. The enclosure 18 and the liner assembly 20 may be collectively referred to as a structural enclosure defining the insulated cavity 24. Similarly, the insulated doors 50 are insulated structures each having an insulated cavity 54 defined between a door enclosure 56 coupled to a door liner 58. Each of the insulated cavities 24 and 54 of the cabinet 12 and the insulated doors 50 generally include one or more insulating materials 60 disposed therein. It is generally contemplated that the insulating materials 60 may be glass-based materials, carbon-based powders, silicon oxide-based materials, silicon dioxide-based materials, insulating gases, and other standard insulating materials 60 known in the art.

[0030] The insulating material 60 substantially fills the insulating cavity 24, thereby forming a substantially continuous layer between the enclosure 18 and the liner assembly 20. Similarly, for one or both doors 50, the insulating material 60 substantially fills the insulating cavity 54, thereby forming a substantially continuous layer between the door enclosure 56 and the door liner 58. The insulating cavities 24 and 54 are filled with the insulating material 60 using loading ports on the cabinet 12 and the insulated door 50, respectively. The cabinet 12 and the insulated door 50 each define an evacuation port for applying a vacuum or negative pressure 26 to the insulating cavities 24, 54.

[0031] Still refer to Figures 1 to 3, defining at least a partial vacuum 26 within the insulated cavity 24, 54, thereby forming the cabinet 12 and the door 50 into a vacuum insulated structure. The at least partial vacuum 26 defines a pressure differential 72 between the exterior 74 of the cabinet 12 and the insulated cavity 24. The pressure differential 72 is used to define an inward compressive force applied to the enclosure 18 and the liner assembly 20 and tends to bias the enclosure 18 and the liner assembly 20 toward the insulated cavity 24. The pressure differential 72 and the inward compressive force are also applied in a similar manner to the door enclosure 56 and the door liner 58 of the insulated door 50 and tend to bias the door enclosure 56 and the door liner 58, respectively, toward the insulated cavity 54.

[0032] The enclosure 18, door enclosure 56, liner assembly 20, and door liner 58 are made of materials that at least partially resist bending, deforming, or otherwise deforming in response to inward compressive forces. Such materials for the enclosure 18, door enclosure 56, liner assembly 20, and door liner 58 include, but are not limited to, metals, polymers, metal alloys, combinations thereof, and / or other similar substantially rigid materials that may be used for vacuum insulation devices and structures.

[0033] Reference Figure 3 , the liner assembly 20 can include a refrigerated liner 20a defining the refrigerated compartment 14 and a freezer liner 20b defining the freezer compartment 16. The refrigerated liner 20a and the freezer liner 20b can also be separate components that, when coupled together, define a mullion gap 80 in the insulated cavity 24 therebetween. The mullion gap 80 can be filled with insulating material 60 and placed under at least a partial vacuum 26. The refrigerated liner 20a and the freezer liner 20b can be biased toward the mullion gap 80 in the insulated cavity 24 in a similar manner as discussed generally with reference to the enclosure 18 and the liner assembly 20.

[0034] In various implementations, the refrigerated liner 20a and the freezer liner 20b can be coupled together separately from the decorative partition assembly 22 in the mullion gap 80. The refrigerated liner 20a and the freezer liner 20b can still define the mullion gap 80 when coupled together. Although the liner assembly 20 is shown as having two separate liners 20a and 20b, the liner assembly 20 can be a single part or structure that defines the refrigerated compartment 14 and the freezer compartment 16. The liner assembly 20 can also be a single structure that defines the refrigerated compartment 14 or the freezer compartment 16. The liner assembly 20 can generally have a shape similar to the enclosure 18 to fit within the enclosure 18 and form the cabinet 12.

[0035] Still refer to Figure 3 as well as Figure 4, the enclosure 18 has a plurality of walls 100, which may include a top wall 102, a bottom wall 104, a rear wall 106, a pair of side walls 108, and a curved wall 110. The bottom wall 104 of the enclosure 18 may be coupled to a base 112. The curved wall 110 and the base 112 of the enclosure 18 at least partially define a mechanical compartment 114. Various equipment components 116 may be positioned on the base 112 within the mechanical compartment 114 below the rear wall 106 and proximate to the curved wall 110 of the enclosure 18. The equipment components 116 positioned within the mechanical compartment 114 may include components of a refrigerant system, which may include portions of a compressor, a condenser, and / or an evaporator assembly. The equipment components 116 may also include controllers, electronic devices, or other components for operating the device 10.

[0036] The enclosure 18 and the liner assembly 20 may define a first through-portion 118 and a second through-portion 120 to provide access for a service connection 122. The enclosure 18 and the liner assembly 20 each define an aperture that aligns with one another to form the first through-portion 118 and the second through-portion 120. The service connection 122 may be an electrical connection, a fluid connection, a refrigeration system connection, and / or other equipment connection between the refrigerated compartment 14 and the freezer compartment 16 and the exterior of the cabinet 12. For example, the service connection 122 may include a suction pipe, a discharge pipe, and a wiring harness.

[0037] Still refer to Figure 3 as well as Figure 5 and Figure 6 , the decorative partition assembly 22 generally couples the enclosure 18 to the liner assembly 20 to form the cabinet 12. It is contemplated that the decorative partition assembly 22 can be coupled to the edge 30 of the enclosure 18 and / or the edge 34 of the liner assembly 20. The decorative partition assembly 22 has a generally rectangular shape, however, it is contemplated that other geometric shapes known in the art can be used. In this manner, the decorative partition assembly 22 can substantially not interfere with access to the refrigerated compartment 14 and the freezer compartment 16 defined by the cabinet 12.

[0038] The trim partition assembly 22 may include a cross member 130 to define apertures 132a and 132b corresponding to the refrigerated compartment 14 and the freezer compartment 16 of the device 10, respectively. The cross member 130 defines a mullion area 134 between the refrigerated compartment 14 and the freezer compartment 16. The trim partition assembly 22 generally defines an outer perimeter 136 extending along an outer portion 138 of the trim partition assembly 22 and an inner perimeter 140 extending along an inner portion 142 of the trim partition assembly 22. The inner perimeter 140 may be concentric with the outer perimeter 138 and extend parallel to the outer perimeter 138. In the example shown, the inner perimeter 140 of the trim partition assembly 22 includes a portion of a perimeter 144 of the refrigerated compartment 14 around the upper aperture 132a and a portion of a perimeter 146 of the freezer compartment 16 around the lower aperture 132b. Additional portions of the perimeters 144, 146 of the compartments 14, 16 extend across the cross member 130. The portions of perimeters 144, 146 may extend parallel to one another across cross member 130. In this manner, perimeters 144 and 146 define openings into compartments 14 and 16, respectively.

[0039] The perimeter 144 of the refrigerated compartment 14 can be a portion of the inner perimeter 140 extending from a first end 148 of the mullion region 134 to a second end 150 of the mullion region 134 around the upper aperture 132a, and extending from the second end 150 of the mullion region 134 to the first end 148 along the cross member 130. Similarly, the perimeter 146 of the freezer compartment 16 can be a portion of the inner perimeter 140 extending from a first end 148 of the mullion region 134 to a second end 150 around the lower aperture 132b, and extending from the second end 150 of the mullion region 134 to the first end 148 along the cross member 130. It is contemplated that in implementations where the apparatus 10 includes one compartment 14 or 16, the inner perimeter 140 can extend around one aperture 132a or 132b.

[0040] Still refer to Figure 3 , Figure 5 and Figure 6 , the trim partition assembly 22 defines a shell recess 28 and a liner recess 32 for receiving an edge 30 of the shell 18 and an edge 34 of the liner assembly 20, respectively. The shell recess 28 may extend along an outer perimeter 136 of the trim partition assembly 22. The trim partition assembly 22 may include a single liner recess 32 extending along an inner perimeter 140 of the trim partition assembly 22, or may include a plurality of liner recesses 32 extending along perimeters 144 and 146 of the compartments 14 and 16. It is contemplated that the trim partition assembly 22 may define a single combined recess extending along the outer perimeter 136 to accommodate both the shell 18 and the liner assembly 20 therein.

[0041] In the example shown, the refrigerated liner groove 32a extends along the perimeter 144 of the refrigerated compartment 14 to receive the refrigerated liner 20a, and the freezer liner groove 32b extends along the perimeter 146 of the freezer compartment 16 to receive the freezer liner 20b. In other words, the refrigerated liner groove 32a extends along the inner perimeter 140 from the first end 148 of the mullion area 134 to the second end 150 of the mullion area 134 around the upper aperture 132a, and along the cross member 130 from the second end 150 of the mullion area 134 to the first end 148. The freezer liner groove 32b extends along the inner perimeter 140 from the first end 148 of the mullion area 134 to the second end 150 of the mullion area 134 around the lower aperture 132b, and along the cross member 130 from the second end 150 of the mullion area 134 to the first end 148. In various implementations, the liner recess 32 may be a single recess 32 that accommodates both the refrigerated liner 20 a and the freezer liner 20 b of the liner assembly 20 .

[0042] Still refer to Figure 5 and Figure 6 , and now also refer to 7A to 9B , the trim partition assembly 22 can include multiple cross-sectional profiles at different locations, including a first cross-sectional profile 170 along a portion 172 of the perimeter 144 of the refrigerated compartment 14 and a second cross-sectional profile 174 along a portion 176 of the perimeter 146 of the freezer compartment 16. The cross member 130 can be the first cross-sectional profile 170, the second cross-sectional profile 174, and / or another third cross-sectional profile. The first cross-sectional profile 170 and the second cross-sectional profile 174 can each define the enclosure recess 28 and the corresponding liner recess 32.

[0043] The enclosure groove 28 in the first cross-sectional profile 170 can be aligned with the enclosure groove 28 in the second cross-sectional profile 174 to form a continuous enclosure groove 28 around the outer perimeter 136 of the trim partition assembly 22. In some implementations, the liner groove 32a defined by the first cross-sectional profile 170 can be aligned with the liner groove 32b defined by the second cross-sectional profile 174 to form a continuous liner groove 32 around the inner perimeter 140 of the trim partition assembly 22. In the example shown, the liner groove 32a defined by the first cross-sectional profile 170 is aligned with the liner groove 32a defined by the cross member 130 to form a liner groove 32a extending around the perimeter 144 of the refrigerated compartment 14. Similarly, the liner groove 32b defined by the second cross-sectional profile 174 is aligned with the liner groove 32b defined by the cross member 130 to form a liner groove 32b extending around the perimeter 146 of the freezer compartment 16.

[0044] Reference Fig. 7A , Fig. 8A and Fig. 9A, the first cross-sectional profile 170 of the trim partition assembly 22 includes an outer wall 180 that, when coupled to the enclosure 18, is generally parallel to and extends away from the enclosure 18. An enclosure groove wall 182 is coupled or connected to the outer wall 180. The enclosure groove wall 182 extends away from the outer wall 180 and then extends parallel to the outer wall 180 to define the enclosure groove 28 therebetween. An inner wall 184 is coupled or connected to the enclosure groove wall 182 and extends to a liner groove wall 186 that defines the liner groove 32a. The liner groove 32a can be offset or recessed from the enclosure groove 28.

[0045] Reference Figure 7B , Figure 8B and Fig. 9B , the second cross-sectional profile 174 of the trim partition assembly 22 includes an outer wall 190 that, when coupled to the enclosure 18, is generally parallel to and extends away from the enclosure 18. An enclosure groove wall 192 is coupled or connected to the outer wall 190. The enclosure groove wall 192 extends away from the outer wall 190 and then extends parallel to the outer wall 190 to define the enclosure groove 28 therebetween. An inner wall 194 is coupled or connected to the enclosure groove wall 192 and extends to a liner groove wall 196 that defines the liner groove 32b. The liner groove 32b may be offset or recessed from the enclosure groove 28.

[0046] In some implementations, the first cross-sectional profile 170 or the second cross-sectional profile 174 can be the same profile around the two compartments 14 and 16. The first cross-sectional profile 170 and the second cross-sectional profile 174 are not limited to the described configuration. The first cross-sectional profile 170 and the second cross-sectional profile 174 can also be configured to include a single groove that accommodates both the enclosure 18 and the liner assembly 20.

[0047] Reference Fig. 8A and Figure 8B , the adhesive 36 can be dispensed or disposed into the shell recess 28 and the liner recess 32 using an adhesive nozzle 200 that is configured to be adjusted around the perimeters 144, 146 of the compartments 14, 16 and / or the outer perimeter 136 of the decorative partition assembly 22. The adhesive nozzle 200 can be coupled to a linear robot or other machine that is configured to move the adhesive nozzle 200 along a defined path. The adhesive nozzle 200 can be moved or positioned along a defined path to dispense and at least partially fill the recesses 28, 32 with the adhesive 36. The adhesive nozzle 200 is not limited to being adjusted by a machine or robot, and can be manually adjusted by a user or operator. For example, the adhesive nozzle 200 can be coupled to a handheld dispenser that is adjusted by a user.

[0048] The adhesive 36 is typically dispensed in an uncured state and undergoes a curing process to produce a cured state. In the uncured state, the adhesive 36 may be a liquid, a fluid, or a semi-solid, wherein the adhesive 36 may be directed to a specific location in the grooves 28, 32 by the adhesive nozzle 200. In the uncured state, the adhesive 36 has not yet undergone a curing process or has partially undergone a curing process. The adhesive 36 may be dispensed by the adhesive nozzle 200 before undergoing or starting a curing process. In some implementations, the adhesive 36 may begin to undergo a curing process in the adhesive nozzle 200 or while being dispensed from it.

[0049] Once introduced into the atmosphere or subjected to an initiated curing process (e.g., using light (e.g., ultraviolet light) or heat, or introducing a catalyst), the adhesive 36 may undergo a curing process. In some implementations, the adhesive 36 may also be a multi-part mixture, wherein the curing process begins when the components are mixed together, thereby causing a chemical reaction to begin. For example, the adhesive 36 may be a two-part epoxy resin having a first component and a second component that begin the curing process when mixed together. In various implementations, the adhesive 36 may include a photoinitiator that reacts with light to catalyze or initiate a chemical reaction. The adhesive 36 may also be thermo-reactive, wherein the curing process is initiated or catalyzed by being baked or heated to initiate and / or complete the curing process.

[0050] During the curing process, the adhesive 36 may adhere to the trim partition assembly 22, the enclosure 18, and / or the liner assembly 20. The adhesive 36 may chemically react with the trim partition assembly 22, the enclosure 18, and / or the liner assembly 20 to create a chemical bond, and / or the adhesive 36 may mechanically couple to the trim partition assembly 22, the enclosure 18, and / or the liner assembly 20. The adhesive 36 is typically cured to a solid or semi-solid state to couple the enclosure 18 and / or the liner assembly 20 to the trim partition assembly 22. The adhesive 36 in the cured state may be an air barrier between the insulation cavity 52 and the exterior of the cabinet 12. The adhesive 36 in the cured state may be airtight or substantially airtight to allow the insulation cavity 52 to maintain at least a partial vacuum 26 therein. The adhesive 36 may also be cured to resist or substantially resist a pressure differential 72 between the insulation cavity 52 and the exterior of the cabinet 12.

[0051] Adhesive 36 may be a structural adhesive that couples decorative partition assembly 22 to enclosure 18 and / or liner assembly 20. Structural adhesives are typically cured to form bonds that can withstand structural loads. Adhesive 36 typically includes monomers and may also include oligomers, photoinitiators, and additional additives (e.g., stabilizers, pigments, inhibitors, etc.) in an uncured state. In a non-limiting example, adhesive 36 may be an epoxy adhesive. Epoxy adhesives may be single-part epoxy resins or two-part epoxy resins. In such an example, the monomer includes free epoxy groups that react with free radicals to form polymer chains during the curing process. The two-part epoxy resin may start the curing process when the two parts are mixed. However, adhesive 36 is not limited to such an example, and may be an acrylic adhesive, a polyurethane acrylate adhesive, a polyurethane adhesive, a silicone adhesive, other adhesives, or combinations thereof that cure to adhere decorative partition assembly 22 to enclosure 18 and / or liner assembly 20 and prevent or reduce air infiltration through it.

[0052] Still refer to Fig. 8A and Figure 8B , and now refer to Fig.10 and Fig.11 , the adhesive nozzle 200 generally dispenses a mixture of the flake additive 38 and the adhesive 36. When dispensed by the nozzle 200, the mixture of the adhesive 36 and the flake additive 38 may be a uniform mixture. The flake additive 38 may be mixed with the adhesive 36 before or during the dispensing process. For example, the adhesive nozzle 200 may include or be coupled to a mixing reservoir or mixing tank configured to mix the adhesive 36 and the flake additive 38. When the adhesive 36 leaves the mixing reservoir, the flake additive 38 may be distributed throughout the adhesive 36. In some implementations, the adhesive nozzle 200 may be configured to mix a continuous feed, a semi-continuous feed, or a batch of adhesive nozzles 200 and the flake additive 38 before or while dispensing the adhesive 36. The flake additive 38 may be mixed with the adhesive 36 in the adhesive nozzle 200. In various implementations, the adhesive 36 and the flake additive 38 may be mixed before being supplied to the adhesive nozzle 200 to be dispensed. However, it is also conceivable that the flake-shaped additive 38 may be added to the adhesive 36 once it has been dispensed in the recesses 28 , 32 .

[0053] The amount of the flake additive 38 included in the adhesive 36 can be between about 1% and about 40% by volume of the total mixture of the adhesive 36 and the flake additive 38. The amount of the flake additive 38 included by volume in the adhesive 36 can also be between about 1% and about 20%, between about 1% and about 10%, between about 1% and about 5%, between about 5% and about 30%, and between about 10% and about 40%. A specific percentage can be selected to balance the fluid shear of the uncured adhesive 36 and the stiffness of the cured adhesive with the reduction of gas permeation through the adhesive 36. For example, the adhesive 36 can have a high viscosity, and the volume percentage of the flake additive 36 can be selected to promote the fluid shear for dispensing the mixture of the adhesive 36 and the flake additive 36. In another non-limiting example, the volume percentage of the flake additive can be used to customize or adjust the stiffness of the adhesive 36 to increase the stiffness of the support and reduce the adverse effects of the adhesive 36 becoming too hard.

[0054] The flake additive 38 is generally composed of a plurality of flakes or flake-like particles 210. Such flake-like particles 210 may include, but are not limited to, mica, glass, kaolin clay, other ceramic materials, combinations thereof, and other similar materials that can be made into fine flake-like particles or nano flakes. In various implementations, the flakes 210 may generally have approximately uniform sizes included in a mixture of the flake additive 38 and the binder 36. It is also contemplated that the flakes 210 may be a range of sizes that may be included in a mixture of the flake additive 38 and the binder 36. The flake additive 38 may be at least one of glass flakes, mica flakes, kaolin clay flakes, other ceramic material flakes, or other fine flake-like particles. It is also contemplated that the flake additive 38 may be at least two of glass flakes, mica flakes, kaolin clay flakes, other ceramic material flakes, or other fine flake-like particles.

[0055] Still refer to Fig.10 and Fig.11 , each flake 210 of the flake additive 38 includes a longitudinal extent 212 extending substantially parallel to the elongated surface 214 of the corresponding flake 210. The flakes 210 may generally have a length 216 extending along the longitudinal extent 212 of about 5 micrometers to about 800 micrometers and a thickness 218 between about 30 nanometers (nm) and about 150 nm. The flakes 210 may also have a length 216 between about 1 micrometer and about 500 micrometers, between about 100 micrometers and about 800 micrometers, between about 100 micrometers and about 500 micrometers, and between about 500 micrometers and about 800 micrometers. The flakes 210 may also have a thickness 218 between about 10 nm and about 200 nm, between about 30 nm and about 150 nm, between about 50 nm and about 100 nm, and between about 80 nm and about 150 nm.

[0056] The flakes 210 generally have a high aspect ratio (length / thickness). The aspect ratio of the flakes 210 of the flake additive 38 may be between about 5 (also expressed as 5:1) and about 5000 (i.e., 5000:1), between about 5 and about 100, between about 5 and about 300, between about 5 and about 500, between about 5 and about 1000, between about 5 and about 2500, between about 100 and about 5000, between about 100 and about 2500, between about 100 and about 1000, and between about 100 and about 300. When the flake additive 38 is glass, the flakes 210 of the flake additive 38 may have an aspect ratio between about 100 and about 1000. When the flake additive 38 is mica, the flakes 210 of the flake additive 38 may have an aspect ratio between about 100 and about 1000.

[0057] When disposed in the grooves 28, 32 of the trim partition assembly 22, the inclusion of the flake additive 38 helps to reduce or prevent gas permeation through the adhesive 36 in a cured state. If gas permeates through the adhesive 36, the at least partial vacuum 26 within the insulating cavity 24 may be degraded, which may adversely affect the insulating properties of the cabinet 12. One way that the flake additive 38 reduces gas permeation is by increasing the distance that a gas 232 or other vapor may need to travel through the adhesive 36 to infiltrate or permeate into the insulating cavity 24. By increasing the distance that the gas 232 travels through the cured adhesive 36 to reach the insulating cavity 24, the potential degradation of the at least partial vacuum 26 through the adhesive 36 can be reduced, minimized, or prevented, thereby reducing, minimizing, or preventing an adverse effect on the insulating properties of the cabinet 12.

[0058] The flake additive 38 is generally suspended by a plurality of polymer chains that form a polymer network 240 of the cured adhesive 36. The polymer network 240 supports or suspends the flakes 210 throughout the adhesive 36 and forms a path 230, while blocking or obstructing other paths through the polymer network 240, thereby reducing the pathways for gas permeation through the adhesive 36. The increased distance in the resulting or remaining path 230 is caused by the flake additive 38 blocking or obstructing other paths, including short paths or shorter paths through the polymer network 240 to the insulating cavity 24. The flake additive 38 also blocks or obstructs multiple paths through the polymer network 240, which limits or reduces the number of paths through the polymer network 240. The increased distance in the path 230 and the reduced number of paths 230 through the polymer network 240 help prevent or reduce gas permeation through the adhesive 36.

[0059] In some implementations, the flakes 210 may be randomly oriented relative to each other within the polymer network 240. In other implementations, the flakes 210 may be arranged within the polymer network 240 or aligned within the polymer network 240. Typically, the elongated surface 214 is aligned in this manner. The flakes 210 may be aligned in the flow direction of injection by the adhesive nozzle 200. The flakes 210 may also be aligned by vibrating or agitating the decorative partition assembly 22, which may align the flakes 210 in the vibration direction and / or cause the heavier portion of the flakes 210 to settle due to gravity. The aligned flakes 210 produce an overlapping structure 242 that increases the length of the path 230. When disposed in the corresponding grooves 28, 32, the overlapping structure 242 of the flakes 210 may be substantially parallel to the cladding 18 and / or the liner assembly 20. When disposed in the corresponding grooves 28, 32, the overlapping structure 242 of the flakes 210 may be substantially perpendicular to the cladding 18 and / or the liner assembly 20.

[0060] Reference Fig.12 , see further Figures 1 to 11 , a flow chart of a method 300 for manufacturing a vacuum insulated structure 10 is shown. The method 300 includes a step 304 of providing a decorative partition assembly 22, the decorative partition assembly 22 defining an outer perimeter 136 and at least one compartment perimeter 144, 146. The decorative partition assembly 22 defines a shell recess 28 extending along the outer perimeter 136 and at least one liner recess 32 extending along at least one compartment perimeter 144, 146. The at least one liner recess 32 may include a refrigerated liner recess 32a and / or a frozen liner recess 32b.

[0061] In step 308, the adhesive 36 in an uncured state (i.e., uncured adhesive) may be mixed with at least one flake additive 38. The flake additive 38 may be mixed with the uncured adhesive 36 in a mixing reservoir coupled to the adhesive nozzle 200. The uncured adhesive 36 and the flake additive 38 may be mixed until the flake additive 30 is evenly distributed throughout the adhesive 36. The uncured adhesive 36 may be mixed with the first flake additive 38 and the second flake additive 38. In step 312, the uncured adhesive 36 is injected into the cladding groove 28 and the liner groove 32, as shown. Fig. 8A and Figure 8B As shown. Adhesive 36 can be injected into the refrigerated liner groove 32a and / or the frozen liner groove 32b. Adhesive 36 can be injected using adhesive nozzle 200. Steps 308 and 316 can be performed simultaneously using adhesive nozzle 200 to mix adhesive 36 and flake additive 38 together.

[0062] In step 316, the edge 30 of the enclosure 18 may be positioned or disposed within the enclosure groove 28 using the uncured adhesive 36, such as Fig. 9A and Fig. 9B In step 320, the edge 34 of the liner assembly 20 may be positioned or disposed within the liner groove 32 using an uncured adhesive 36, such as Fig. 9A and Fig. 9B As shown. The liner assembly 20 may include a refrigerated liner 20a and a frozen liner 20b. The edge 34a of the refrigerated liner 20a may be disposed in the refrigerated liner groove 32a using an uncured adhesive 36, and the edge 34b of the frozen liner 20b may be disposed in the frozen liner groove 32b using an uncured adhesive 36. In steps 320 and 324, the edge 30 of the shell 18 and / or the edge 34 of the liner assembly 20 may be disposed in corresponding grooves 28, 32 without uncured adhesive 36, and adhesive 36 may be added to the grooves 28 and 32 around the shell 18 and the liner assembly 20, respectively.

[0063] In step 324, the uncured adhesive 36 disposed in the enclosure groove 28 and at least one liner groove 32 is cured to form a polymer network 240 that suspends the flake additive 38 to reduce the permeation of the gas 232 through the adhesive 36. The uncured adhesive 36 can be cured by heating the uncured adhesive 36. The uncured adhesive 36 can also be cured by providing a light source that interacts with the photoinitiator included in the adhesive 36 to activate the photoinitiator. In step 328, at least a partial vacuum 26 can be or be drawn in the insulation cavity 24 defined by the enclosure 18 and the liner assembly 20 coupled together with the decorative partition assembly 22. Step 328 can also include coupling the door 50 to the cabinet 12, adding a refrigeration system, and otherwise completing the assembly of the device 10. Without departing from the teachings of this document, the steps of the method 300 can be performed in any order, simultaneously, in parallel, repeated, omitted, etc.

[0064] The use of the present device can provide various advantages. For example, the flake additive 38 mixed with the adhesive 36 and disposed in the grooves 28, 32 helps to reduce or prevent gas permeation through the adhesive 36. By preventing or reducing gas permeation through the adhesive 36, the at least partial vacuum 26 drawn in the insulation cavity 24 will be maintained or better maintained for a longer time. By maintaining at least a partial vacuum 26 for a longer time, the device 10 can have a longer operating life before the insulation performance of the device 10 is reduced or lost. In addition, by reducing or preventing gas permeation through the adhesive 36, the permeation of water vapor through the adhesive 36 will be reduced. The reduction of water vapor in the insulation cavity 24 can increase the life of the insulation material 60 therein. By increasing the life of the insulation material 60, the life of the insulation performance of the cabinet 12 can also be increased. In addition, the flake additive 38 can provide some rigidity in the adhesive 36, and therefore provide greater rigidity in the decorative partition assembly 22 and the cabinet 12. In addition, due to the increased rigidity of the adhesive 36, a larger vacuum 26 can be drawn in the insulation cavity 24. The greater vacuum 26 in the insulation cavity 24 may increase the insulation properties of the cabinet 12 by reducing the heat transfer path (ie, the gas within the insulation cavity 24). Additional benefits or advantages may be achieved and / or obtained.

[0065] The devices disclosed herein are further summarized in the following paragraphs and may also be characterized by any and all combinations of the various aspects described herein.

[0066] According to one aspect of the present invention, a vacuum insulation device includes a cabinet defining at least one compartment. The cabinet includes a shell and a liner assembly. The shell and the liner assembly define an insulation cavity therebetween. The insulation cavity is under at least partial vacuum. A decorative partition assembly is coupled to the shell and the liner assembly. The decorative partition assembly defines a shell groove for receiving an edge of the shell and at least one liner groove for receiving at least one edge of the liner assembly. An adhesive is disposed in the shell groove and the at least one liner groove, the adhesive sealing the insulation cavity. The adhesive includes a flaky additive to reduce gas permeation therethrough, thereby maintaining the at least partial vacuum in the insulation cavity.

[0067] According to another aspect, the platelet-shaped additive is at least one of glass flakes, mica flakes, and kaolin clay flakes.

[0068] According to yet another aspect, the aspect ratio between the length and the thickness of each particle of the plate-like additive is between 5 and 500.

[0069] According to another aspect, at least one compartment includes a first compartment and a second compartment, wherein the liner assembly includes a first liner defining the first compartment and a second liner defining the second compartment.

[0070] According to yet another aspect, at least one liner groove includes a first liner groove and a second liner groove. The decorative partition assembly defines an outer perimeter and an inner perimeter and includes a cross member. The shell groove extends along the outer perimeter of the decorative partition assembly. The first liner groove extends along a first portion of the inner perimeter and across the cross member to align with the perimeter of the first compartment. The second liner groove extends along a second portion of the inner perimeter and across the cross member to align with the perimeter of the second compartment.

[0071] According to another aspect, a trim partition assembly defines an outer perimeter and an inner perimeter. A sheathing groove extends along the outer perimeter of the trim partition assembly, and at least one liner groove extends along at least a portion of the inner perimeter of the trim partition assembly.

[0072] According to yet another aspect, the platelet-shaped additive is uniformly distributed in the adhesive.

[0073] According to another aspect, the adhesive is an epoxy resin.

[0074] According to another aspect of the present invention, a refrigeration device includes a decorative partition assembly that defines an outer shell recess and a refrigerated liner recess. An adhesive is disposed in the outer shell recess and the refrigerated liner recess, wherein the adhesive includes a flaky additive to reduce air infiltration through the adhesive. The outer shell has an edge disposed within the outer shell recess of the decorative partition assembly using the adhesive. The refrigerated liner has an edge disposed within the refrigerated liner recess of the decorative partition assembly using the adhesive. The refrigerated liner defines a refrigerated compartment.

[0075] According to another aspect, the outer shell and the refrigerated liner define an insulated cavity therebetween, wherein at least a partial vacuum is defined within the insulated cavity.

[0076] According to yet another aspect, the platelet-shaped additive is at least one of glass flakes, mica flakes, and kaolin clay flakes.

[0077] According to another aspect, an adhesive includes a polymer network having a platelet-like additive suspended therein to reduce gas permeation through the polymer network.

[0078] According to yet another aspect, a freezer liner has an edge disposed within a freezer liner recess defined by a trim partition assembly. The freezer liner defines the freezer compartment.

[0079] According to another aspect of the present invention, a method for manufacturing a vacuum insulated cabinet includes: providing a decorative partition component assembly, the decorative partition component assembly defining a shell groove extending along an outer periphery and at least one liner groove extending along a periphery of at least one compartment; mixing an uncured adhesive with a flake additive; and injecting the uncured adhesive with the flake additive into the shell groove and the at least one liner groove. The method also includes positioning an edge of the shell in the shell groove using the uncured adhesive, positioning an edge of at least one liner in the at least one liner groove using the uncured adhesive, and curing the uncured adhesive in the shell groove and the at least one liner groove to form a polymer network, the polymer network suspending the flake additive to reduce gas permeation therethrough.

[0080] According to yet another aspect, a method comprises the step of mixing an uncured adhesive with a flake-shaped additive simultaneously with the step of injecting the uncured adhesive with the flake-shaped additive by using an adhesive nozzle coupled to a mixing reservoir.

[0081] According to another aspect, a method includes the step of mixing an uncured adhesive with a flake-like additive, the step including mixing the uncured adhesive with the flake-like additive until the flake-like additive is evenly distributed with the uncured adhesive.

[0082] According to yet another aspect, the method comprises the step of mixing an uncured binder with a flake-like additive to form a mixture wherein the flake-like additive is between 1% and 40% by volume of the mixture of the uncured binder and the flake-like additive.

[0083] According to another aspect, a method includes drawing at least a partial vacuum within an insulated cavity defined between a containment shell and at least one liner.

[0084] According to yet another aspect, at least one liner groove includes a refrigerated liner groove and a frozen liner groove. The method includes the step of injecting an uncured adhesive with a flake additive, the step including injecting the uncured adhesive with the flake additive into the refrigerated liner groove and injecting the uncured adhesive with the flake additive into the frozen liner groove.

[0085] According to another aspect, at least one liner includes a refrigerated liner and a freezer liner. The method includes the step of positioning an edge of at least one liner within at least one liner groove, the step including positioning the edge of the refrigerated liner within the refrigerated liner groove and positioning the edge of the freezer liner within the freezer liner groove.

[0086] One of ordinary skill in the art will appreciate that the described disclosure and other components of construction are not limited to any particular material. Unless otherwise described herein, other exemplary embodiments of the invention disclosed herein may be formed from a variety of materials.

[0087] For purposes of this invention, the term "coupled" (and all its forms) generally refers to the connection of two components (electrical or mechanical) directly or indirectly to one another. Such connection may be fixed or removable in nature. Such connection may be achieved through the two components (electrical or mechanical) and any additional intermediate members that are integrally formed as a single unitary body between the two components or with the two components. Unless otherwise specified, such connection may be permanent in nature or may be removable or releasable.

[0088] It is also important to note that the construction and arrangement of the elements of the present invention shown in the exemplary embodiments are only illustrative. Although only a few embodiments of the present invention are described in detail in this disclosure, those skilled in the art who read this disclosure will readily understand that many modifications (e.g., changes in the size, dimensions, structure, shape and proportion of various elements, the value of parameters, the installation arrangement, the use of materials, colors, orientations, etc.) can be made without substantially departing from the novel teachings and advantages of the narrated subject matter. For example, an element represented as being integrally formed can be composed of multiple parts or an element represented as multiple parts can be integrally formed, the operation of the interface can be reversed or otherwise changed, the length or width of the structure and / or member or connector or other element of the system can be changed, and the nature or number of adjustment positions provided between elements can be changed. It should be noted that the elements and / or assemblies of the system can be made of any of a variety of materials that provide sufficient strength or durability, with any of a variety of colors, textures, and combinations. Therefore, all of these modifications should be included within the scope of the present invention. Without departing from the spirit of the present invention, other substitutions, modifications, changes, and omissions can be made to the design, operating conditions, and arrangements of the desired and other exemplary embodiments.

[0089] It should be understood that any process described or any step in a process described can be combined with other disclosed processes or steps to form structures within the scope of the present invention. The exemplary structures and processes disclosed herein are for illustrative purposes and should not be interpreted as limiting.

Claims

1. A vacuum insulation device, comprising: A cabinet defining at least one compartment, the cabinet comprising: Encapsulation; a liner assembly, wherein the containment shell and the liner assembly define an insulated cavity therebetween, and wherein at least a partial vacuum is defined in the insulated cavity; and a trim partition assembly coupled to the enclosure and the liner assembly, wherein the trim partition assembly defines an enclosure recess for receiving an edge of the enclosure and at least one liner recess for receiving at least one edge of the liner assembly; and An adhesive is disposed in the cladding groove and the at least one liner groove, the adhesive sealing the insulation cavity, wherein the adhesive includes a flake additive to reduce gas permeation therethrough to maintain the at least partial vacuum in the insulation cavity. 2 . The vacuum insulation apparatus according to claim 1 , wherein an aspect ratio between a length and a thickness of each particle of the flake-shaped additive is between 5 and 500.

3. The vacuum insulation apparatus of claim 1, wherein the at least one compartment comprises a first compartment and a second compartment, and wherein the liner assembly comprises a first liner defining the first compartment and a second liner defining the second compartment.

4. A vacuum insulation device according to claim 3, wherein the at least one liner groove includes a first liner groove and a second liner groove, and wherein the decorative partition component assembly defines an outer periphery and an inner periphery and includes a cross member, and further wherein the shell groove extends along the outer periphery of the decorative partition component assembly, the first liner groove extends along a first portion of the inner periphery and across the cross member to align with the periphery of the first compartment, and the second liner groove extends along a second portion of the inner periphery and across the cross member to align with the periphery of the second compartment.

5. The vacuum insulation apparatus of claim 3, wherein the decorative partition component assembly defines an outer perimeter and an inner perimeter, and wherein the shell groove extends along the outer perimeter of the decorative partition component assembly, and wherein the at least one liner groove extends along at least a portion of the inner perimeter of the decorative partition component assembly. The vacuum insulation apparatus according to claim 1 , wherein the flake-shaped additive is uniformly distributed in the adhesive. The vacuum insulation apparatus according to claim 1 , wherein the adhesive is an epoxy resin.

8. The vacuum insulation apparatus according to any one of claims 1 to 7, wherein the flake-shaped additive is at least one of glass flakes, mica flakes, and kaolin clay flakes.

9. A refrigeration device, comprising: a decorative partition assembly defining an outer shell recess and a refrigerated liner recess; an adhesive disposed in the outer shell recess and the refrigerated liner recess, wherein the adhesive includes a flake additive to reduce air infiltration through the adhesive; an outer shell having an edge disposed within the outer shell groove of the decorative partition member assembly using the adhesive; as well as A refrigerated liner has an edge disposed within the refrigerated liner recess of the trim partition assembly using the adhesive, wherein the refrigerated liner defines a refrigerated compartment.

10. The refrigeration appliance of claim 9, wherein the outer enclosure and the refrigerated liner define an insulating cavity therebetween, and wherein at least a partial vacuum is defined in the insulating cavity.

11. The refrigeration device according to claim 9, wherein the flake additive is at least one of glass flakes, mica flakes and kaolin clay flakes.

12. The refrigeration device according to claim 9, further comprising: A freezer liner has an edge disposed within a freezer liner recess defined by the trim partition assembly, wherein the freezer liner defines a freezer compartment.

13. A refrigeration device according to any one of claims 9 to 12, wherein the adhesive comprises a polymer network having the flake-like additive suspended therein to reduce gas permeation through the polymer network.

14. A method for manufacturing a vacuum insulation cabinet, comprising: providing a trim partition assembly defining a sheathing groove extending along an outer perimeter and at least one liner groove extending along a perimeter of at least one compartment; mixing the uncured adhesive with the flake additive; injecting the uncured adhesive with the flake-shaped additive into the cladding groove and the at least one liner groove; positioning an edge of the cladding within the cladding groove using the uncured adhesive; positioning an edge of at least one liner within the at least one liner groove using the uncured adhesive; as well as The uncured adhesive in the cladding groove and the at least one liner groove is cured to form a polymer network that suspends the platelet additive to reduce gas permeation therethrough.

15. The method of claim 14, wherein the step of mixing the uncured adhesive with the flake-shaped additive is performed simultaneously with the step of injecting the uncured adhesive with the flake-shaped additive by using an adhesive nozzle coupled to a mixing reservoir.

16. The method of claim 14, wherein the step of mixing the uncured adhesive with the flake additive comprises: The uncured adhesive is mixed with the flake additive until the flake additive is evenly distributed with the uncured adhesive.

17. The method according to claim 14, further comprising: At least a partial vacuum is drawn within an insulated cavity defined between the containment shell and the at least one liner.

18. The method of claim 14, wherein the at least one liner groove comprises a refrigerated liner groove and a frozen liner groove, and wherein the step of injecting the uncured adhesive with the flake additive comprises: injecting the uncured adhesive with the flake additive into the cold storage liner groove; as well as The uncured adhesive with the flake additive is injected into the freeze liner groove.

19. The method of claim 18, wherein the at least one liner comprises a refrigerated liner and a frozen liner, and wherein the step of positioning an edge of the at least one liner within the at least one liner groove comprises: positioning an edge of the refrigerated liner within the refrigerated liner groove; as well as Positioning the edge of the freezer liner within the freezer liner groove.

20. The method of any one of claims 14 to 19, wherein the step of mixing the uncured binder with the platy additive forms a mixture in which the platy additive is between 1% and 40% by volume of the mixture of the uncured binder and the platy additive.

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